Structure and method for installing staircase treads
A stair tread structure includes a tread body comprised of a core having a plurality of layered glued plywood members, top and bottom veneer layers glued to the core for minimizing warping of the tread, and an elongate hardwood leading edge formed with an inside ridge to fit into the core and veneer layers in a tongue and groove manner. Included is a jig/template for onsite trimming of the stair tread ends as needed for fitting of an end-cap, thus providing proper onsite fitting of each stair tread.
The background of the invention will be discussed in two parts.
FIELD OF THE INVENTIONThe present invention relates to staircase treads, and more particularly to structure and method for onsite remodeling of existing staircase tread and stair carriage.
PRIOR ARTMost stairways in modern American homes were built by framing carpenters with the stairs covered by carpet. To improve the appearance of their staircases homeowners often replace the carpet with full length stair treads. However, because of the original rough carpentry work proper fitting of stair treads during remodeling is usually very difficult. A search of the prior art has not disclosed the structure and method for installing staircase treads disclosed in the present invention. However, structure and methods of interest are disclosed in U.S. Pat. No. 5,985,398 issued to Bellegarde on 16 Nov. 1999, and No. 6,596,362 issued to Chung on 22 Jul. 2003. Also of interest is US 2006/0196129 A1 (Alfonso Lin) published on 7 Sep. 2006.
U.S. Pat. No. 5,985,398 to Bellegarde discloses a conventional staircase tread structure having a transverse elongated nose member and a plurality of elongate tread pieces glued laterally to each other, the nose member having a curved front protruding flange glued to a core layer. The tread body is made up of multiple tread pieces that are glued laterally to each other before the nose member is applied and bonded. This procedure however is unsatisfactorily tedious and time consuming. Further, simply gluing the tread body pieces together with the nose member does not provide sufficient bonding to prevent inadequate disassociation of the tread pieces over time.
U.S. Pat. No. 6,596,362 to Chung discloses a staircase tread structure having an elongate nose member, a plurality of tread bodies, and an end member. The nose member has a semi-circular front flange with each of the tread bodies made up of a core layer with laminated upper and lower surface layers. The core layer includes middle pieces of various sizes that are glued together at the middle section thereof with two lateral end pieces of different sizes bonded with the middle pieces.
Published application US 2006/0196129 A1 (Alfonso Lin) discloses a staircase tread structure having a tread body made up of a core layer, a plurality of lateral connecting members, a tread end member, a plurality of external connecting sheets, and a nose member. The core layer and the tread end member are made up of board bodies of lower quality materials such as recycled wood, plywood, or sawdust which is processed and bonded into one piece with the connecting members, external connecting sheets, and tread nose member glued thereto.
Although adequate for their intended use, these prior art structures do not disclose the advantages inherent in the present invention. It is thus an aspect of the present invention to provide improved staircase tread structure and method of installation which may be used at initial fabrication of the staircase treads, or for onsite remodeling of existing staircases. Other aspects and advantages will become readily apparent from a reading of the specification when taken in conjunction with the drawings in which like reference numerals refer to like elements in the several views.
SUMMARYThe structure of the present invention includes a tread body comprised of a core having a plurality of layered glued plywood members, veneered top and bottom layers glued to the core for minimizing warping of the tread, and an elongate hardwood leading edge formed with an inside ridge to fit into the core and veneer layers in a tongue and groove manner. Included is a jig/template for onsite trimming of the stair tread ends as needed for fitting of an end-cap, thus providing proper onsite fitting of each tread.
The present invention is primarily useful for onsite remodeling of an existing staircase, however it can be used equally well at initial fabrication of stairways. Existing staircases were mostly installed by framing carpenters with the stairs to be covered by carpet, the rough framing having imprecise tolerances, usually being ¼ to ½ inch. This rough carpentry work makes it difficult to install and properly fit specialized stair treads after removal of the carpet. For instance, most walls are not sufficiently straight which requires each tread end to be cut and carefully fitted to prevent unacceptable gaps between the stair tread and the wall. The finish carpenter must butt each stair tread to the wall, scribe a line, and then cut or shape the stair tread wall end to fit tightly against the wall. These and other problems have shown prior art methods of replacing stairway carpet with specialized stair treads to be inadequate. There is thus an existing need for improved structure and method for onsite remodeling of existing stair tread and stair carriage.
Referring to the drawings in general, and initially to
The nose member 14 is of solid hardwood and fitted and glued to the assembled plywood core 11 and veneer layers 12, 13 by a tongue and groove joint, generally designated 14a in
The many variances in length as well as other adjustments that are required to properly install the staircase treads 10, using “pre-made” exact length staircase treads with the nose members already attached, are very difficult to work with. On the open side of the staircase, where the handrail balusters/spindles are to be installed, each stair tread 10 is scribed where the wall comes up under the stair tread. After scribing this open side, the installer must add roughly 1¼″ to the measurement to allow for end cap 15 to overhang the leading edge 14. Otherwise the tread ends 15 would be flush with the wall. This scribed line must be made to be at a 90 degree angle (square) again because of the rough cuts by the original framers. The treads 10 of the present invention are fabricated longer than necessary so they can be cut, scribed and trimmed to exact length as needed to attach the hardwood end-cap 15 onsite. Onsite fitting of end-caps 15 is accomplished by use of the stair end trimming jig/template 80 as will be described.
When jig/template 80 is adjusted for the width of the tread 10 and then clamped down onto the stair tread 10 the cutting edge will be automatically set square at 90 degrees. Thus, jig/template 80 is formed with substantially identical ends having reversed cutouts for trimming either end of the tread 10 to accept an appropriately trimmed end cap 15. Fitting of the trimmed end-cap 15 to the stair tread 10, after the stair tread 10 has been trimmed, has been indicated in
In accordance with the present invention there has been set forth and described a preferred embodiment, however, it is to be understood that other modifications may be maid within the spirit and scope of the invention.
Claims
1. A staircase structure for installation of staircase treads, comprising;
- a core layer made up of multiple board bodies integrally bonded into one piece, said core layer bonded intermediate of a top and bottom layer to form a core body;
- a leading edge member bonded to the front edge of said core body;
- an end cap bonded to a selected side of said core body;
- said top and bottom layers assembled and bonded with the grains thereof in the same directions; and
- said multiple layers of said core are assembled and bonded with the grains thereof in alternate directions.
2. The structure of claim 1 wherein said leading edge includes a lateral coupling projection and said core layer includes a lateral coupling groove for receiving said leading edge coupling projection to provide tongue and groove coupling, and said top and bottom layers are precisely mated with said leading edge to provide a continuous smooth surface.
3. The structure of claim 2 wherein said end cap, said core body and said leading edge are trimmed and assembled to form a miter joint.
4. The structure of claim 3 wherein said top and bottom layers have surfaces of veneered hardwood.
5. The structure of claim 4 wherein said core layers are fabricated of layered and bonded plywood.
6. The structure of claim 5 wherein said leading edge and said end cap are fabricated of hardwood.
7. A staircase structure comprising:
- a tread body having a core layer, a top and bottom layer, and a laterally extending elongate leading edge member;
- said core layer having multiple plywood members integrally bonded into one piece, said core layer bonded intermediate of said top and bottom layers;
- said leading edge member bonded to the combination of said core layer and said top and said bottom layers with said top and bottom layers fitting over said core layer to precisely mate with said leading edge to provide a continuous smooth surface; and
- an end cap bonded to said tread body, said tread body and said end cap matingly trimmed and fitted together to form a miter joint.
8. The staircase structure of claim 7 wherein said core layer is fabricated of layered and glued plywood, said top and bottom layers have surfaces of veneered hardwood, and said leading edge and said end cap are fabricated of hardwood.
9. The staircase structure of claim 7 wherein said top and bottom layers are assembled and bonded with the grains thereof in the same directions and said multiple layers of said core are assembled and bonded with the grains thereof in alternate directions.
10. The staircase structure of claim 9 wherein said leading edge member includes a lateral coupling projection and said core layer includes a matching lateral coupling groove whereby said leading edge member and said core layer are coupled to provide a tongue and groove coupling.
11. A method of providing a staircase tread including a laterally extending core body having a multiple board core layer, top an bottom layers bonded to said core layer, a leading edge member bonded to the front edge of said core body and an end cap bonded to a select side of said core body wherein in assembly
12. The method of claim 11 wherein said core layer is fabricated of layered and bonded plywood.
13. The method of claim 11 wherein said top and bottom layers have surfaces of veneered hardwood.
14. The method of claim 11 wherein said leading edge and said end cap are fabricated of hardwood.
Type: Application
Filed: Apr 19, 2010
Publication Date: Oct 20, 2011
Inventor: Wolfgang De Glorgio (El Cariso Village, CA)
Application Number: 12/799,019
International Classification: E04F 11/108 (20060101); E04F 21/26 (20060101); E04F 11/02 (20060101);